CN104170244A - Electrical submersible pump monitoring and failure prediction - Google Patents

Electrical submersible pump monitoring and failure prediction Download PDF

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Publication number
CN104170244A
CN104170244A CN201280061920.3A CN201280061920A CN104170244A CN 104170244 A CN104170244 A CN 104170244A CN 201280061920 A CN201280061920 A CN 201280061920A CN 104170244 A CN104170244 A CN 104170244A
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China
Prior art keywords
pump
dynamic behaviour
current
analysis device
electric current
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CN201280061920.3A
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Chinese (zh)
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CN104170244B (en
Inventor
穆罕默德·纳比尔·努依-梅希蒂
艾哈迈德·亚辛·布哈姆森
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Saudi Arabian Oil Co
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Saudi Arabian Oil Co
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01VGEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
    • G01V3/00Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation
    • G01V3/02Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation operating with propagation of electric current
    • G01V3/06Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation operating with propagation of electric current using ac
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00Survey of boreholes or wells
    • E21B47/008Monitoring of down-hole pump systems, e.g. for the detection of "pumped-off" conditions
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01VGEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
    • G01V3/00Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation
    • G01V3/38Processing data, e.g. for analysis, for interpretation, for correction
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02PCONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P31/00Arrangements for regulating or controlling electric motors not provided for in groups H02P1/00 - H02P5/00, H02P7/00 or H02P21/00 - H02P29/00

Abstract

Current supplied to electrical submersible pumps in wells is monitored, and signal processing based on wavelet analysis and phase diagram analysis is performed on the data obtained from monitoring. An incipient malfunction of the electrical submersible pump, such as one due to scale build-up in and around the pump, can be detected at an early stage.

Description

Submersible electric pump monitoring and failure predication
Inventor: MOHAMED NABIL NOUI-MEHIDI
AHMED?YASIN?BUKHAMSEEN
Technical field
The present invention relates to performance monitoring and the failure predication of the submersible electric pump in oil well.
Background technology
Oil-immersed pump is used in the well at different depth and flow velocity place for Petroleum Production.Described pump is generally electronic, is called as submersible electric pump (ESP).ESP is the one being called as in the various ways of artificial lift (artificial lift).ESP is arranged in the pipeline in oil well and is set to the form of production of relative efficiency rate.
The ESP system using in Petroleum Production is included in the terrestrial components at production wellhead or platform place and is arranged on the underground assembly in production pipeline or the sleeve pipe at production stratum place in oil well.Terrestrial components comprises that electric machine controller and land cable and transformer are with the underground assembly to down-hole by transmission of power.Underground assembly in oil well comprises pump, pump motor, Fluid Sealing and service cable.
The operational depth place of down-hole ESP pump in oil well the power also providing by electrodynamic pump machine (it receives operational power by service cable from ground) in the oil well fluid being pumped is provided formation fluid is pumped into ground.
At stratum production period, in ESP, oil country tubular good and other underground equipments and around there is the mineral deposits from formation fluid, cause recurrent problem.Mineral deposits is called as incrustation scale.In ESP unit in most common failure reason one is the scale build-up in pump stage, forms gradually incrustation scale final block fluid flow near pump impeller blade.Incrusted deposit thing causes the reduction gradually of the efficiency of pump until finally produce failure of pump.
The problem that incrustation scale and other underground conditions and long-time running bring finally causes the fault of down-hole ESP assembly (normally pump).Conventionally analyzed by cause and the reason to ESP component faults after pulling out or take out from oil well in system.Be that detailed DIFA (overhaul & accident analysis) processes at ESP by the common analytical method using after oil well removes, wherein each assembly of ESP group is carefully analyzed to look for out of order essence.Experience shows that common more than 20% failure cause is that electrical fault causes.
But as indicated, the accident analysis of this form can only be after fault occurs, down-hole or underground ESP assembly are carried out after oil well takes out.ESP fault and it is removed and cause oil well production to be ended from oil well.Oil well production only replace ESP underground system be installed in oil well in time could recover.Therefore oil well production is being dispatched workover rig and is being transported it into the time durations interruption that the required time of oil well adds installation replacement ESP underground system.
Summary of the invention
In brief, the invention provides new and the improved equipment based on the analysis of pump electric current being monitored to the performance of the submersible electric pump in oil well.Equipment according to the present invention comprises the frequency spectrum analyser of pump current energy, and the wavelet analysis device of the pump current waveform of the time variation of identification pump electric current.Described equipment is also included in the pump amperometry device of the dynamic behaviour of pump period identification pump, and forms the phase space analysis device of the measured value of the dynamic behaviour of the pump of identifying based on the fluctuation of pump electric current.Thereby the graphic interface of described equipment forms instruction from described multiple analyzers and detects pump performance disturbance with monitoring pump performance.
The present invention also provides new and the improved method based on the analysis of pump electric current being monitored to the performance of the submersible electric pump in oil well.The frequency spectrum of pump current energy is analyzed, and the analyzed time with identification pump electric current of waveform of pump electric current changes.Pump electric current is analyzed to identify the dynamic behaviour of pump period pump, forms the measured value of the dynamic behaviour of the pump of identifying based on the fluctuation of pump electric current.Form the instruction of described analysis result for monitoring pump performance to detect the disturbance of pump performance.
Brief description of the drawings
Fig. 1 is the schematic diagram of the submersible electric pump in oil well.
Fig. 2 is the current of electric that the flows to submersible electric pump curve chart along with the example record of passage of time.
Fig. 3 be for submersible electric pump according to the schematic diagram of diagnostic signal processing components of the present invention.
Fig. 4 A is the drawing of the example Fourier transform figure of the current of electric record of submersible electric pump.
Fig. 4 B is the drawing of the example small echo map of current of the current of electric record of submersible electric pump.
Fig. 5 processes the example phase space plot obtaining according to the present invention.
Embodiment
With reference to figure 1, the permission that shows the position that is formed on the some perforations 12 in sleeve pipe 14 in oil well 10 enters the submersible electric pump group P of entrance or introducing portion 15 from oil and other hydrocarbon fluids on the stratum 16 in subsurface reservoir.Sleeve pipe 14 can also be arranged in the sleeve pipe of the larger diameter in oil well 10 by lining.The pump part 20 of submersible electric pump group P is immersed in the fluid in sleeve pipe 14.At the well depth place of perforation 12, submersible electric pump group P in sleeve pipe 14, be hung on pipeline 22, make pump part 20 can as drive as shown in 24 or pumping sleeve pipe 14 in fluid to ground collection facility.
Pump part 20 comprises the centrifugal pump stage being driven by alternating current pump motor 26 of right quantity.Pump motor 26 receives the operation electrical power from the suitable power supply 30 on ground by cable 28.Pump motor 26 drives the axle that runs through suitable sealing with the centrifugal pump stage of the pump part 20 of driving submersible electric pump group P.Pump part 20 is traditional and comprises a lot of impellers and diffuser level.
The submersible electric pump group P of Fig. 1 is equipped with monitoring or register system 32 continues to record about the different operating parameter of submersible electric pump group P to guarantee the good function of pumping system and related sensor.As the control of submersible electric pump group P and a part for monitoring scheme, the current waveform of operand power that offers pump motor 26 by cable 28 such as, together with other operating parameters (fluid velocity, pump speed, introducing and blowdown presssure etc.) by lasting record.
The waveform 40 being recorded in Fig. 2 according to the example pump electric current of the current amplitude of time illustrates.Electric current wave recording 40 show as pump group fault shown in 42 before the example of ESP current of electric of several time-of-weeks.Several days times before fault as seen from Figure 2, pump current waveform 40 shows the essence variation of pump performance trend.
According to the present invention, diagnostic processor 44 (Fig. 3) is carried out the signal analysis in advance of pump motor operation and is monitored the pump motor likelihood of failure causing due to scale build-up.This signal analysis can be the computer implemented method on all-purpose computer, or can be digital signal processing circuit or the chip of special configuration, or both combinations.Diagnostic processor 44 process receive from register system 32 nurse one's health and be converted to the pump current signal record for the form of digital processing by modulate circuit 45 (Fig. 3).Diagnostic processor 44 is analyzed pump electric current and records to identify dynamic behaviour and the performance of pump motor 26 (Fig. 1).
According to the present invention, diagnostic processor 44 comprises and multiplely illustrating be recorded in module that the variation of the several aspects in motor current signal analyzes event pump operated with dynamic tracing and that will indication pump motor before physical fault may break down by register system 32.As shown in Figure 3, analyzed by Fourier transform analyzer module 46, wavelet transformation module 48 and phase place attractor module 50 by the time series of the collected motor current signal of register system 32.
Fourier transform analyzer module 46 is to analyze the processor of pump current signal waveform by Fourier analysis as digital spc signal processor or dedicated processes circuit operation.Fourier transform analyzer module 46 provide the power that is present in pump electric current or energy according to the measured value of the frequency change on its frequency spectrum.Fourier transform analyzer module 46 provides pump current waveform in the instruction of determining the characteristics of signals in time window.The Fourier analysis of analyzer module 46 produces the energy density of the power spectrum of single-frequency scope.Fourier transform analyzer module 46 is preferably carried out the signal processing technology that is called fast Fourier transform in a preferred embodiment.If the power spectrum being obtained by fast Fourier transform analysis allows to determine the characteristic frequency of the pump electric current that the frequency range that exists in time before failure of pump pump electric current in pump group P and identification exists.
Fig. 4 A shows the example of the Fourier transform figure obtaining from module 46.In actual applications, the figure as Fig. 4 A is colored to illustrate in greater detail related data.The Fourier transform figure of Fig. 4 A shown the characteristic frequency of current of electric record and presented maximum amplitude, and these maximum amplitudes play a decisive role to the frequency spectrum that shows the singular structure in the signal corresponding with the scale buildup of the extra load as on ESP motor shaft.
Wavelet transformation analysis device module 48 (Fig. 3) is carried out wavelet analysis to the pump electric current record being provided by register system 32.Wavelet transformation analysis device module 48 can be the processor pump current signal waveform is analyzed by wavelet transformation analysis equally as digital spc signal processor or dedicated processes circuit operation.
Wavelet transformation analysis device module 48 is to determine the module of the signal characteristic variation of pump current waveform in time domain, and Fourier analyzer module 46 is as above, and the signal characteristic of analyzing the pump current waveform in frequency domain changes.The wavelet analysis of wavelet analysis device module 48 allows to follow the trail of the change in time and space of signal in different time scale.
The wavelet transformation that shows the continuous signal s (t) of the pump electric current changing according to time t is provided by equation (1):
C ( τ , a ) = - 1 a ∫ - ∞ + ∞ ψ ( t - τ a ) s ( t ) dt - - - ( 1 )
Wherein Ψ is female small echo, and it is that completely integrable divides function.
Wavelet analysis in module 48 is carried out by flexible and the female small echo Ψ of translation.Parameter a in equation (1) is to flexible relevant and be inversely proportional to frequency.The parameter a that changes wavelet analysis in analyzer 48 changes centre frequency and the small echo time parameter of female small echo Ψ.As by narration, operation parameter a instead of frequency represent the result of the wavelet analysis in wavelet analysis device 48 thus.
Parameter τ be translation or time shifting parameter.Parameter τ specifies the time location of small echo, adjusts parameter τ and makes small echo translation on analyzed pump current signal.For example,, by equation (2)
ψ ( t ) = ( 1 - t 2 ) exp ( - t 2 2 ) - - - ( 2 )
The small echo that is called " sombrero function " providing is passable, for example, in the time that signal s (t) has high fluctuation, is selected as female small echo.In wavelet analysis device 48, the parameter a of variation is compressed to lower numerical value and allows the high fdrequency component of pump current waveform to analyze, and it is relevant to low frequency component that parameter a is expanded into larger numerical value.
Fig. 4 B is the exemplary graph of the wavelet transformation output of the parameter a of the different time shifts of drawing in different frequency grade that formed according to the time scale figure of the isocorrelate a/ Δ t of parameter a by wavelet analysis device module 48.
In the example of the wavelet transformation figure shown in Fig. 4 B, isocorrelate curve chart carrys out normalization to highlight the peak value of correlation values for the highest correlation values.The center of the contour area corresponding with peak value has clearly shown in the periodic structure that appears at different time scale.Should present and regular texture in the abnormal corresponding signal of extra load by ESP axle or the caused signal pattern owing to the scale buildup in system of moment of torsion for periodicity in crest is integrated of time scale.Can also see that these peak values have the a/ Δ t value of the progress of different expression system dynamic behaviours, the i.e. progress of the incrustation scale load on rotating shaft.
Diagnostic processor 44 also comprises dynamic behaviour analyzer module 50, and wherein the clock signal corresponding with the fluid-phase of the certain fluidised form through pump group P dynamically embedded to be identified for setting up the signal fractal dimension of dynamic attractor depicted in figure 5.The data of the current of electric record obtaining based on next free watch-dog 32, can identify pump performance and change.Pump current waveform carries out mark by the module 51 multiple characteristic frequencies that increase that superpose in time in behavior analyzer module 50.The existence of the clock signal increasing makes it possible to the relevant attractor of result of signal identification expression pump performance after turning back to stable state.For example, the signal processing method of interactive information method can be used to estimate that the each seasonal effect in time series time delay recording is to build the attractor relevant to the time delay of each introducing.Appropriate time delay is that of the first minimum value corresponding to the interactive information function calculating from time series.
Diagnostic processor 44 also comprises phase diagram reconstruction module 52, wherein as the dynamic behaviour of the pump of the measured value instruction being provided by watch-dog 32 is determined from embedding signal by the reconstruction of phase diagram.Signal merge module 51 and phase diagram reconstruction module 52 can be equally all the processors as the dynamic behaviour of the identification pump group P of digital spc signal processor or dedicated processes circuit operation.
The example of the reconstruction phase diagram being formed by module 52 is presented at Fig. 5 and illustrates.As the analysis to this data of collecting from current of electric record of Fig. 5 shows that the fluctuation of being recorded has low-down frequency, this is illustrated in the accumulation gradually of the incrustation scale in different pump stages.The phase space building from recorded signal shown in Fig. 5 is rebuild to draw and is presented at the not long ago clear typical chaos trend of electric current record of failure of pump.Drawing in Fig. 5 clearly presents the sub-basin of typical suction, its from Dynamic Definition, disclosed with ESP motor shaft on the signal that is linked of the extra load that causes of the scale build-up by gradually in the existence of regular texture.The combination of Fig. 4 A, Fig. 4 B and Fig. 5 is drawn and has clearly been highlighted the variation of ESP current of electric trend and the extra load on the motor shaft existing along with the scale build-up in different ESP levels is dynamically shown.
Diagnostic processor 44 comprises graphic interface 54, the demonstration of its pump current data of crossing with formation processing from the treated data of each reception of Fourier analyzer module 46, wavelet analysis device module 48 and phase diagram reconstruction module 52.The frequency spectrum obtaining from Fourier analyzer module 46 that image conversion interface 54 forms as shown in Figure 4 A shows.Image conversion interface 54 also forms demonstration as shown in Figure 4 B and forms phase space reconstruction figure as shown in Figure 5 based on rebuild the result that module 52 produces from phase space plot based on the result from wavelet analysis device 48.Graphic interface is user friendly environment, and it allows user's demonstration to expect the drawing obtaining and the variation of keeping a close eye on primary signal from said method.
Graphic interface 54 provides the result forming in diagnostic processor 44 as the display separating or window as separating output.The analysis of described three kinds of demonstrations provides instruction to show that any disturbance being present in pump motor electric current record also also provides and may cause the pump performance of failure of pump and the instruction in advance of behavior.Diagnostic processor 44 allows the incrustation scale of monitoring on submersible electric pump group P by the disturbance size in identification current of electric record to increase.
Monitor constantly the performance of submersible electric pump group P the incipient fault that prediction causes due to scale build-up according to diagnostic process of the present invention.The current of electric recording, can record the faint fluctuation in this electric current, to show the variation due to the motor load that on pump motor axle, scale build-up causes before fault.This scale build-up affects local axle moment of torsion therefore loss integrated motor power.These variations can be identified by current of electric loss.The dynamic characteristic that in advance signal analysis to current of electric data provided by the present invention can disclose the pump current signal existing in the time that incrustation scale starts in pump stage Rapid Accumulation changes.
Therefore, the invention provides physical fault event a few days ago or the real-time diagnosis system of the likelihood of failure of a few weekly forecasting ESP systems.This makes it possible to control well production decision better.For example, if by doping scale build-up by the fault causing by diagnostic tool provided by the present invention, can plan multiple action and prevent or delay failure of pump.This class action for example comprises that reduction motor speed is to increase the production cycle (even if output is lower).Therefore, production can just dispatch workover rig with during replacing submersible electric pump group or the work of planning acidification continue with during removing incrustation scale.This class action can be avoided expensive inspection and minimize the production loss causing due to shut-down.
The present invention is the disturbance in the performance of Real time identification submersible electric pump group thus.Initial stage that can the pump motor fault that caused power loss variations causes in the scale build-up due in pump stage detects.Therefore can carry out aggressive control and plan that corrective action is to prevent the fault of whole pump the pump operation time.The present invention especially can also minimize the downtime that pump is repaired.
The present invention is fully described to make those of ordinary skill in the art can reappear and obtain the mentioned result of the present invention herein.However, those skilled in the art according to invention herein can carry out not herein described modification, by these alternative applications in definite structure or manufacture process, require the request theme in claims; This class formation should be covered by scope of the present invention.
What it should be noted that and recognize is to exist in the situation that does not depart from the spirit and scope of the present invention of being set forth as claims the present invention described above in detail to make and improving and amendment.

Claims (19)

1. the equipment based on the analysis of pump electric current being monitored to the performance of submersible electric pump in oil well, comprising:
The frequency spectrum analyser of pump current energy;
The wavelet analysis device of the pump current waveform that the time of identification pump electric current changes;
The pump amperometry device of the dynamic behaviour of identification pump period pump;
Form the phase space analysis device of the measured value of the dynamic behaviour of the pump of identifying based on pump current fluctuation; With
Thereby form and indicate the graphic interface that detects pump performance disturbance with monitoring pump performance from described multiple analyzers.
2. equipment according to claim 1, wherein said frequency spectrum comprises fast Fourier transform analysis device.
3. equipment according to claim 1, wherein said wavelet analysis device comprises adjustable small echo is applied to described pump current waveform to analyze the wavelet transformation analysis device of frequency component of pump electric current.
4. equipment according to claim 1, wherein said dynamic behaviour analyzer comprises samples to described pump current waveform with different time interval and the pump current waveform of being sampled is carried out to the analyzer that interactive information is analyzed.
5. equipment according to claim 3, the dynamic behaviour of wherein said dynamic behaviour analyzer based on described pump is further the identification that described phase space analysis device forms attractor.
6. equipment according to claim 1, wherein said phase space analysis device forms instruction in the phase space plot of the attractor of identifying being provided by described dynamic behaviour analyzer.
7. the equipment based on the analysis of pump electric current being monitored to the performance of submersible electric pump in oil well, comprising:
The frequency spectrum analyser of pump current energy;
The wavelet analysis device of the pump current waveform that the time of identification pump electric current changes; With
Thereby form and indicate the graphic interface that detects pump performance disturbance with monitoring pump performance from described multiple analyzers.
8. equipment according to claim 7, wherein said frequency spectrum comprises fast Fourier transform analysis device.
9. equipment according to claim 7, wherein said wavelet analysis device comprises adjustable small echo is applied to described pump current waveform to analyze the wavelet transformation analysis device of frequency component of pump electric current.
10. the equipment based on the analysis of pump electric current being monitored to the performance of submersible electric pump in oil well, comprising:
The frequency spectrum analyser of pump current energy;
The pump amperometry device of the dynamic behaviour of identification pump period pump;
Form the phase space analysis device of the measured value of the dynamic behaviour of the pump of identifying based on pump current fluctuation; With
Thereby form and indicate the graphic interface that detects pump performance disturbance with monitoring pump performance from described multiple analyzers.
11. equipment according to claim 10, wherein said dynamic behaviour analyzer comprises samples to described pump current waveform with different time interval and the pump current waveform of being sampled is carried out to the analyzer that interactive information is analyzed.
12. equipment according to claim 11, the dynamic behaviour of wherein said dynamic behaviour analyzer based on described pump is further the identification that described phase space analysis device forms attractor.
13. equipment according to claim 10, wherein said phase space analysis device forms instruction in the phase space plot of the attractor of identifying being provided by described dynamic behaviour analyzer.
14. 1 kinds of methods based on the analysis of pump electric current being monitored to the performance of submersible electric pump in oil well, comprising:
Analyze the frequency spectrum of described pump current energy;
The waveform of analyzing described pump electric current changed with the time of identifying described pump electric current;
Analyze the dynamic behaviour of described pump electric current with pump described in identification pump period;
Form the measured value of the dynamic behaviour of the described pump of identifying based on pump current fluctuation; And
Thereby the instruction that forms analysis result detects described pump performance disturbance with monitoring pump performance.
15. methods according to claim 14, the step of wherein said analysis spectrum comprises the step of fast Fourier transform analysis.
16. methods according to claim 14, the step of the waveform of wherein said analysis pump electric current comprises adjustable small echo is applied to described pump current waveform to analyze the step of frequency component of pump electric current.
17. methods according to claim 14, the step of the measured value of the dynamic behaviour of the pump that wherein said formation is identified comprises samples to described pump current waveform with different time interval and the pump current waveform of being sampled is carried out to the step that interactive information is analyzed.
18. methods according to claim 17, the step of the measured value of the dynamic behaviour that wherein said formation is identified comprises the identification that forms attractor based on the dynamic behaviour of described pump.
19. methods according to claim 14, the step of the measured value of the dynamic behaviour that wherein said formation is identified is included in the phase space plot of the attractor of identifying being provided by described dynamic behaviour analyzer and forms instruction.
CN201280061920.3A 2011-12-13 2012-12-12 Submersible electric pump monitors and failure predication Expired - Fee Related CN104170244B (en)

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PCT/US2012/069224 WO2013090416A2 (en) 2011-12-13 2012-12-12 Electrical submersible pump monitoring and failure prediction

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